(BE-SL & -DS) Single Level & Double Stack Operator Aboard Battery Extractors – Parts & Service Manual (IOP-400)

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Preface

This manual is to be used to service SINGLE LEVEL (BE-SL) as well as DOUBLE STACK (BE-DS) Battery Extractors.

Any views not specifically stated otherwise are of the Single Level Extractor. The parts listed are common for Single Level (BE-SL) and Double Stack (BE-DS) unless otherwise noted in the notes column of the Parts Lists. See Example Below.

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00158001-10	CHAIN-ROLLER-#60		BE-SL ONLY	4
	00158001-12	CHAIN-ROLLER-#60		BE-DS ONLY	4

For Items or Assemblies that are unique to only the SL or DS, it will be designated as such on the diagram and have a separate, corresponding parts list for that diagram.

When servicing HIGH PERFORMANCE (BE-DS-HP) models, refer to the High Performance Option section for all parts unique to High Performance Units. If a particular part is not found in the High Performance Option section, refer tot the Standard Parts Section(s) of this manual.

TP-606 – Safety & De-Energization Procedures

General Safety

Read and understand all instructions and warnings before using or servicing this equipment. Keep these instructions for future reference.

• Battery Extractor (BE) units shall only be operated by suitable persons of at least 18 years of age, who have been trained in the proper and safe operation of the BE and expressly certified/charged, in writing, by the user or their representative.
• Only one person is permitted to travel on the BE at any time.
• BE units shall only be used indoors in an industrial setting on a hard, nonslip, and level floor without defects including but not limited to holes, gouges, cracks, drains or obstacles comprised of concrete or other suitable industrial material meeting the minimum requirements specified by BHS as well as any local requirements.
• A licensed structural engineer should be consulted prior to installing a BE on any building level other than the ground floor.
• BE units are not designed to be shipped or transported after initial delivery.
• Failure to follow these instructions and warnings may result in property damage, personal injury or death.

Work Area

• Keep work area clean and well lit. Cluttered work areas and poor lighting can lead to accidents.
• Clean up/contain any fluid spills immediately to prevent slips or falls.
• Be aware of potential hazards when performing any service or maintenance to the unit.

Service & Maintenance

Service personnel shall wear Personal Protective Equipment (PPE) appropriate for the task being performed.

Lockout/Tagout Lockout/tagout the BE per your corporate policy, if damaged or not functioning properly. Lockout/tagout and de-energize all systems prior to performing any maintenance or service to unit.

Lead-Acid Battery Explosion Hazard DO NOT allow open flames or sparks of any kind near a battery. Highly explosive gas is generated when charging a battery that can remain in battery cells for extended periods of time after charging is complete. Always wear appropriate PPE including rubber apron, gloves, boots and full face shield when performing service or maintenance to any lead-acid batteries. DO NOT place metal or other conductive objects on top of battery. Arcing may occur causing damage to the battery and/or serious personal injury or death. Use only chargers matching the voltage and amperage of the battery being charged. Overcharging a battery can cause damage to the battery, charger and/or serious personal injury or death. Turn off charger before disconnecting battery from charger. Arcing between battery and charger connectors can cause damage to the connectors and/or serious personal injury or death.

Hydraulic Hazards AVOID HIGH PRESSURE FLUIDS-Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. DO NOT use your hand. Any fluid injected into the skin under high pressure should be considered a serious medical emergency despite an initial normal appearance of the skin. There will be a delayed onset of pain, and serious tissue damage may occur. Medical attention should be sought immediately.

	Electromagnet Hazard Units equipped with magnetic extraction generate strong magnetic fields. Persons with pacemakers SHOULD NOT operate or be in close proximity to equipment during operation. Failure to comply with this direction could result in serious personal injury or death.

Operational Safety

• Only personnel trained in the proper and safe operation of BE units may operate or service the BE.
• Operators shall wear appropriate PPE suitable for working with industrial lead-acid batteries while operating the BE (See Lead-Acid Battery Explosion Hazard section).
• All data plates, warning labels, placards, etc. shall be in place and legible at all times. Contact BHS for re-placement data plates, warning labels, placards or instructions.
• All users and service personnel shall be familiar with the meaning and risks associated with all data plates, warning labels, etc.
• All operators and service personnel shall be aware of potential crush and shear points while operating or servicing the BE.
• Keep hands and arms inside the operator compartment while operating the BE.
• Remove BE from service if damaged, defective, or operating improperly (or becomes such while operating) until repairs can be made to correct any problem(s).
• All operators shall be aware of the location of the end stops in the travel path to prevent driving the BE into the end stops.

Do's and Don'ts

• DO NOT exceed the maximum capacity of the BE.
• DO NOT modify or fit the BE with attachments without prior, written approval from BHS.
• DO NOT perform any maintenance or service to the BE with a battery loaded on the BE.
• DO NOT allow anyone to ride in or on the BE.
• DO NOT operate the BE with any guard or cover removed unless required for maintenance or repair.
• Disconnect the BE from all power sources before attempting to perform service or maintenance to the unit.
• DO NOT drive the BE into the end stops.
• DO NOT operate the BE if disengaged from the guidance track.
• DO NOT allow a battery to exit the BE when a lift truck or battery stand is not present to accept the battery.
• DO NOT rotate the arm onto a battery such that any part of the extractor arm, vacuum cup or magnet contacts the top of the battery.
• DO NOT allow anyone to enter the area under the carriage without the service stands properly installed.
• DO NOT use the BE in a manner for which it is not intended. Some examples of prohibited use are but not limited to:
  • To transport people
  • As a vehicle jack
  • To lift loads greater than its rated load capacity
  • Where unintentional movement may exist
  • Having direct contact with foodstuffs
  • In a potentially explosive atmosphere

De-Energization

1. Fully lower the BE roller bed or position the roller bed on service stands if service requires the bed be raised. See Figures 1 & 2.

	Failure to properly support the roller bed when performing service under the BE could result in injury from the roller bed lowering unexpectedly.

FIGURE 1

FIGURE 2

2. Turn key on dashboard to the “OFF” position. See Figure 3.

3. Disconnect power to the extractor or shut off the electrical branch circuit breaker.

Failure to disconnect electrical power to the BE could result in electrical shock. Serious personal injury or death will occur.

4. Actuate all hydraulic levers in both directions to re-lease any stored hydraulic pressure. See Figure 4.

Failure to release any stored hydraulic pres-sure could result in injury from: Escaping hydraulic fluid under high pressure (see HYDRAULIC HAZARDS in the GENERAL SAFETY section). Unexpected movement of hydraulic components.

FIGURE 4

Labels & Placards

Operators should be familiar with the meaning of the following labels and placards found on the BE to ensure proper and safe operation.

	Read and understand instruction manual prior to use.
	Lockout before servicing.
	Extractor arm positioning arrows
	DO NOT operate with guards or covers removed
	NO riders allowed.
	DO NOT operate by or in close proximity to people with pacemakers.
	Strong Magnet Field Hazard Attraction between magnet and metallic objects can crush. Keep unsecured metallic objects away from magnet. De-energize and lockout/tagout before servicing.
	Chain Entanglement Hazard Moving chains and sprockets can crush and cut. Keep hands and fingers clear. Do not operate with guards removed. De-energize and lockout/tagout before servicing.
	Electrical Hazard Energized components can cause electrical shock. De-energize and lockout/tagout before servicing.
	Horn (If equipped)
	Vacuum Off/On (If equipped)
	Magnet Off/On (If equipped)
	Powered Roller Cutout Override (If equipped)
	Rack Level Assist Indicator (If equipped)

	Far Power Rollers
	Arm Travel
	Near Power Rollers

BE-SL & DS UNITS ONLY

Drive Forward/Reverse	Platform Raise/Lower	Arm Rotation Near/Far

BE-TS & QS UNITS ONLY

Operating Controls & Instructions

Operation Overview

• All operators should be familiar with the operator console of the extractor before performing any battery changes. The controls of the console are simple and well marked. It consists of six, manually operated, hydraulic control valves and a three position selector switch which controls the left and right vacuum cups (or optional magnets).
• The operator shall make certain there are no persons or obstacles in the extractor path prior to traveling forward or reverse.
• All manual valves are moved in the direction of the function travel which it controls with exception of the lift/lower valve, which is pulled toward the operator for "up" and pushed away for "down."
• In the event of any failure or malfunction, step off the dead-man switch or press the E-stop button and all functions will stop immediately, locking all hydraulics in place.
• The extractor arm must be in the center of the carriage or the unit will not travel forward or reverse.
• To ensure smooth operation, all valve movements should be made in a slow, deliberate motion.
• Only one key should be provided to operate the extractor.
• When leaving the machine, the operator shall turn off the key switch, remove the key and logout out of the IIoT (if equipped) to prevent unauthorized use
• Ensure all the batteries and cables are properly stored in the battery stands prior to moving the BE.
• The BE is designed to carry only one battery in each compartment on the carriage.
• When loading the BE, position the batteries in the center of the compartments on the powered rollers to prevent any battery movement when transporting.
• Ensure there are no projections outside of the carriage before moving the BE.

Operating Instructions

Pre-Change Out Preparation

1. Position lift truck for change out in designated area.

2. Remove all battery restraints and disconnect battery cables following manufacturers guidelines. (Be sure to position battery cables so as not to be damaged by the battery during change out.)

3. Board battery extractor and close safety gate. (Gate must be fully closed or unit will not operate.)

4. Turn key switch to "ON" position.

5. Log in on the HMI display (if equipped with BE-IIoT package).

6. Depress foot pedal.

Discharged Battery Removal

1. Move extractor forward or reverse to position center of empty compartment with center of lift truck battery compartment. (Lead roller of extractor is equipped with a centering groove. Users may find it beneficial to mark center of lift truck compartment to aid in alignment.)

2. Align extractor's roller compartment height with lift truck's battery compartment.

3. Rotate extractor arm into battery compartment aligned in Step 2.

4. Move extractor arm toward battery until vacuum cup/magnet contacts battery

DO NOT force cup/magnet into battery after initial contact with battery is made.

5. Energize vacuum/magnet by turning selector switch to proper direction, left or right.

6. Move extractor arm away from lift truck toward center of extractor roller bed, removing discharged battery. (Battery should be pulled past first three idler rollers onto first or second powered roller.)

7. Turn off vacuum/magnet and move extractor arm away from battery 1" to 2".

8. Rotate extractor arm out of battery compartment into opposite compartment (if empty) and center arm in carriage.

9. Move battery into center of compartment using powered rollers.

Charged Battery Retrieval

1. Locate charged battery for appropriate type of lift truck being changed.

2. Raise battery extractor roller compartment to proper level to gain access as needed to disconnect desired battery from its charger and disengage battery safety stop.

ALWAYS be sure charging has been completed and charger is not still charging battery. Dangerous sparking/arcing can occur if battery is unplugged from charger while charging.

3. Move extractor to appropriate rack position and align empty roller compartment with the center of the battery storage rack compartment. (The battery safety stop of each compartment is the center of that compartment and should be used for alignment with the groove in the lead roller of the battery extractor compartment.)

4. Rotate arm into empty compartment (if not already positioned there.)

5. Move extractor arm toward battery until vacuum cup/magnet contacts battery.

6. Energize vacuum cup/magnet by turning selector switch to proper direction, left or right.

DO NOT force cup/magnet into battery after initial contact with battery is made.

7. Move extractor arm away from battery rack toward center of extractor roller bed, removing charged battery. (Battery should be pulled past first three idler rollers onto first or second powered roller.)

8. Turn off vacuum/magnet and move extractor arm away from battery 1" to 2".

9. Rotate extractor arm out of battery compartment into fully vertical position.

10. Move battery into center of compartment using powered rollers.

Discharged Battery Return

1. If required, adjust extractor compartment height to battery rack level with open battery compartment. Drive extractor to align roller compartment containing discharged battery with open battery compartment.

2. Return discharged battery to battery rack using powered rollers.

NOTE: In most instances, batteries can be deposited into battery racks in one motion using only powered rollers. When this does not work, the battery may need slight assistance from extractor arm. To do this, rotate arm into compartment such as one would if removing battery from rack. If extractor is vacuum equipped, position top edge of cup slightly higher than edge of battery (or over lifting eye if so equipped) to prevent cup from adhering to battery - No vacuum/magnet is necessary for pushing. DO NOT activate vacuum/magnet switch. Slowly push battery into rack until fully into compartment.

3. Engage battery safety stop and connect battery to charger as required.

Charged Battery Installation

1. Lower extractor to fully lowered position.

2. Drive extractor back to lift truck and align roller compartment containing charged battery as performed in steps 1 and 2 of Discharged Battery Removal.

3. Move charged battery toward lift truck compartment by using powered rollers, verifying precise battery alignment.

Many batteries are a tight fit into lift truck battery compartments. Care MUST be taken to ensure alignment is precise to avoid damage to battery, lift truck, and/or battery extractor.

4. Adjust extractor vertically as well as horizontally, if needed.

5. Insert battery into lift truck as far as possible using only the powered rollers.

6. Rotate extractor arm into compartment and SLOWLY push battery into lift truck. (Be sure to watch battery cables for interference.)

7. Return extractor arm to center of roller bed and lower extractor to fully lowered position. Drive extractor out of immediate area.

8. Turn off key switch, remove key from switch, log out on the HMI display (if equipped with BE-IIoT package) and carefully exit extractor.

9. Secure newly installed battery in lift truck and reconnect battery cables.

10. Return lift truck to service.

CAUTION IMAGE HERE	DO NOT drive the BE into the travel path end stops. The end stops are designed to prevent the BE from accidentally traveling beyond its designated travel path. Driving the BE into the end stops will cause the BE to stop suddenly, possibly causing damage to the end stop, the BE and/or personal injury.

Optional Powered Roller Cutout Operation

Units equipped with optional Powered Roller Cutout, the powered roller override button must be depressed in addition to actuating the hydraulic valve when a battery disrupts the photo eye(s) at the edge of the battery compartments while using the powered rollers to transfer batteries on and off of the battery extractor.

IIoT Equipped Units

Units shipped after February, 2020 are equipped with BEIIoT (Industrial Internet of Things) package.

Operators must log in to the BE-IIoT system using the HMI (Human Machine Interface) display located on the dashboard to operate the extractor.

When finished operating the extractor, the operator should log out of the BE-IIoT to prevent unauthorized access and/ or operation of the extractor.

Manual Unloading

Lockout/tagout and de-energize all equipment prior to manually unloading any battery.

In the event of power loss or an operational malfunction of the BE not allowing a battery to be unloaded using normal operating procedures, it is recommended a battery be removed from the BE using certified and approved vertical extraction methods and devices.

Read, understand and observe all safety warnings and procedures related to the vertical extraction device(s) being used.

Should the status of the BE not allow for safe vertical extraction (due to position in the battery aisle or level of the inner carriage), only repairs required to safely maneuver the BE to a position allowing for safe vertical extraction should be made. Once any batteries are safely unloaded, any remaining repairs can be made.

Extreme care should be taken when working under or around equipment supporting elevated loads. Unexpected movement of the equipment could cause the load and/or equipment to fall. ALWAYS be sure devices of adequate size and strength are in place to prevent any personnel working under the elevated load from being crushed. Serious personal injury or death will occur.

Spare Parts Kits

Refer to the appropriate Spare Parts Kit (vacuum equipped units - Pt# BE-SPKV-SLDS, magnet equipped units - Pt# BESPKM- SLDS) for the list of items recommended by BHS to have on hand for BE-SL or BE-DS models to minimize any downtime due to minor breakdowns that may occur under normal operating conditions.

Use only BHS approved replacement parts.

BHS offers many replacement parts kits containing relevant or related parts when replacing certain individual parts or replacing any obsolete / upgraded parts.

BHS also offers a supplement hose kit (Pt# 80242005) which contains an assortment of hoses allowing any hose on the extractor to be replaced immediately with a temporary hose of equal length or longer. After the extractor is back up and running, the failed hose can be taken to have an exact replacement made. Once the new hose is made and installed, the temporary hose can be returned to the kit for future use.

Go to www.bhs1.com and click "Parts" for all the latest parts kits and corresponding installation instructions (if applicable).

BHS recommends that a full maintenance inspection report similar to the one provided be done at least once a month. Any parts found to be excessively worn or damaged should promptly be replaced unless said parts pose a safety risk to the operator and/or extractor, in which case the unit should be removed from service until the problem(s) are remedied (See Operator's Daily Checklist.)

NOTE: Spare parts kits contain parts for the most current machine design/configuration. Due to continuous design and manufacturing updates and improvements, not all the parts in the spare parts kits may be compatible with older units. Consult factory when ordering spare or replacement parts for existing units in the field to ensure part compatibility.